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Removing Engine
NOTE During subsequent operations the ground cable must be disconnected from the battery. The engine is removed together with the gearbox down. Leave the key in the ignition to prevent steering wheel lock. Before dismantling the power unit is recommended to remove the front wheels. In this way, the car can be lowered on the lift, leaving between the casing of the brake discs and the floor a few centimeters. Thus, during operation reach the optimal level of all components in the engine compartment. After the installation of the engine must be returned to all the cable clamps, remove or cut for its dismantling. To avoid damage to the parts removed, use the container for removed parts. Some components in the vehicle can not or difficult to disassemble without removing the engine. Therefore, before removing motor is necessary to determine all defective parts and after removal of the engine to replace them. |
ATTENTION When all installation work, in particular in the engine compartment, because of the tight layout, consider the following. Motorways of all kinds (such as fuel, hydraulic absorber, activated carbon, cooling systems, circuit conditioning systems, brake lines, vacuum hoses) and electrical wiring must be routed as they were originally laid. Provide space for all moving or hot components.
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Before removing the fault memory of all control units. Disconnect the ground cable from the battery when the ignition is off. Remove the engine cover.
Unscrew the screw A, pull the air filter upwards from the attachment (Fig. 2.253). Remove the air filter housing with mass flow sensor and connection tube. Disconnect all of the necessary vacuum hoses, or, if available, plug-in connection on the solenoid valve unit. Remove the battery and battery holder frame. Remove the wiper arms. Remove the cover plenum chamber.
Vehicles without anti-theft alarm system Unlock the connecting plugs from the engine control unit and disconnect.
Cars with anti-theft alarm system Unlock the connecting plugs from the engine control unit and disconnect.
Continuation of the assembly operations for all vehicles Remove the sealing sleeve harness / engine control unit. Open the latches cabling. Remove the engine wiring harness from the cabling on the spar and place it on the engine. Remove the fuel feed pipe, fuel return pipe and the coolant hose.
ATTENTION Fuel and fuel lines may have a high temperature. Besides the fuel system is under pressure before opening the system place a cloth around the connection and reduce the pressure by slowly unwinding of these compounds |
| Fig. 2.85. Fixing the cable generator to the fuse holder
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Remove the cable from the central switchboard of the car (Fig. 2.85).
Put the cables. Remove the terminals, disconnect and release the rest of the available power wire from the engine / transmission. Disconnect all connectors from the engine, vacuum and intake hoses from the engine.
Vehicles with front-wheel drive Remove the drive gear from the gearbox.
Vehicles with four-wheel drive Remove the drive gear from the gearbox.
Continuation of the assembly operations for all vehicles Remove the working cylinder of the hydraulic clutch. Remove noise insulation. Remove the plug on the sensor level and oil temperature. Unclip the harness from the sensor level and oil temperature on the auxiliary frame. Drain the coolant. Lead frame radiator in the service position. Completely remove the intake pipe from the additional heater. Remove the coolant hoses from the auxiliary heater. Disconnect all other hoses on the engine cooling system. Remove the right power off and remove the left drive shaft from the transmission.
Vehicles with four-wheel drive Remove front propeller shaft tube.
Vehicles with particulate filter Remove the connecting pipe clamp front desk / front silencer. Remove the subframe with the steering.
NOTE The engine is removed together with a diesel particulate filter set down. |
Vehicles without particle filter Remove the exhaust pipe from the turbocharger, remove the clamp and remove the double exhaust pipe.
Continuation of the assembly operations for all vehicles
To remove and install the engine, not razgermetiziruya refrigerant circuit, remove the V-ribbed belt. Unscrew air conditioner compressor from bracket. Secure air conditioner compressor on the radiator frame so that the tube / hose loop air conditioning systems were strained.
NOTE To avoid damage to the capacitor, and the pipes and hoses loop air conditioning system, it must be ensured that the lines and hoses have been laid without tension, bends and kinks. |
Screw the lock to the engine mounting nut and bolt M10h25 / 8.8 with a torque of about 40 Nm to the engine block. Install retainer for the motor rack for the engine and gearbox.
Slightly lift the engine and transmission via rack for engine and gearbox (Fig. 2.95).
NOTE To remove securing bolts use ladder. |
| Fig. 2.96. Fixing the upper engine mount bracket
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Remove the cushions on the top side of the engine from the engine support (Fig. 2.96).
Remove the cushions on the side of the gearbox bracket from gearbox (Fig. 2.255). Lower engine and gearbox down.
NOTE Lower the engine and transmission to be careful to avoid damage to the body. |
Mounting engine on assembly stand For assembly work the engine must be secured by a lock for the engine and gearbox on the jig mounting stand or retainer for the engine and gearbox.
The order of execution of works Separate the gearbox.
Hang the lifting tackle in the right way and lift the engine using a crane or a crane with a rack for engine and gearbox (Fig. 2.256). From the pulleys 2 hole guide in position 1. Flywheel side of the guide hole 4 in the 8-position.
ATTENTION Use belay pins on the hooks and locking pins. |
NOTE Holes 1-4 carrier strips pointing in the direction of belt pulleys. |
Count holes in rails being off the hook. Secure the engine with a lock for the engine and gearbox on the jig mounting stand or retainer for the engine and gearbox.
Installation Instructions Installation is performed in reverse sequence, with the following. Check clutch release bearing for wear and replace if necessary. Lightly lubricate the gear teeth of the drive shaft with grease. Check the engine block-fitting sleeves for centering the engine / gearbox, if necessary, install them. Install the engine support is free from internal stresses (shake), if necessary, remove the engine from the body pillow.
Vehicles with four-wheel drive Install the front propeller shaft tube.
Continuation of the assembly operations for all vehicles Fill in cooling liquid. Observe safety precautions when operating a test drive. Perform a test drive and then interrogate the fault memory.
Tightening torques
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